Leveling Machine Roller Adjustment for Variable Blank Conditions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manually adjusting rollers in leveling machines for various work materials is difficult, time-consuming, and requires skilled labor, as it involves accommodating different widths, gauges, and types, which can lead to inefficiencies in producing flat blanks.
Innovation Solution
An automated system for leveling machines that includes a control unit and user interface to present blank conditions, receive user input, determine roller arrangements, and move rollers accordingly, enabling precise and efficient adjustment of rollers based on selected blank conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of rollers is used to accommodate various work materials, then the leveling machine can handle different widths, gauges, and types, but the adjustment process becomes difficult and time-consuming
Solution Approach 1:
The system stores pre-determined roller arrangements for different work material types, gauges, and widths. When a material is selected, the corresponding roller configuration is automatically retrieved and applied, eliminating the need for manual adjustment and reducing setup time while maintaining versatility.
Solution Approach 2:
The leveling machine automatically determines and applies the appropriate roller arrangement based on the selected work material parameters. The system self-adjusts without requiring operator intervention, thereby reducing adjustment time while maintaining the ability to handle various materials.
2Adaptability or versatility
If manual adjustment of rollers is used to accommodate various work materials, then the leveling machine can handle different widths, gauges, and types, but a high level of skill is required
Solution Approach 1:
The system automatically determines the appropriate roller arrangement based on the selected work material parameters and executes the adjustment without operator intervention. This eliminates the need for skilled manual adjustment while maintaining the ability to accommodate various materials.
Solution Approach 2:
The manual mechanical adjustment process is replaced with an automated control system that uses sensors and actuators to determine and apply roller arrangements. This substitution eliminates the need for operator skill while maintaining adaptability to different materials.
3Loss of time
If automated roller adjustment is implemented, then adjustment time is reduced and ease of operation is improved, but the system complexity increases
Solution Approach 1:
The control system serves multiple functions: it stores roller arrangement data, determines appropriate configurations based on material parameters, and executes adjustments. This multi-functionality consolidates what would otherwise require separate systems into a single integrated unit, reducing overall complexity while achieving automation.
Solution Approach 2:
The system uses pre-stored digital representations (copies) of roller arrangements for different material types. Instead of requiring complex real-time calculations, the system retrieves and applies these pre-determined configurations, simplifying the control logic while maintaining automation benefits.
Data Source
AI summary
A leveling machine is automatically adjustable. A plurality of blank conditions are presented at a user interface. A selection of a first blank condition is received at the user interface. An arrangement of the rollers is determined based on the selection of the first blank condition. The rollers are moved based on the determined arrangement.